Method and apparatus for routing cable in existing pepelines

ABSTRACT

Carriers and support means for routing cable structures in existing pipelines are disclosed, the carriers comprising coiled or folded cylinders or section thereof bearing or adapted to bear a cable support means are disclosed, as well as a method of fixing such carriers to the interior of pipelines, and routing cable structures by means of such devices and methods.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The present invention pertains to routing cable within existingpipelines, and to apparatus suitable for use therein.

[0003] 2. Background Art

[0004] In rural environments, routing of a variety of cable,particularly communications cable, may be accomplished by overheadrouting on “telephone” poles or by routing underground in newlyinstalled conduits or tunnels. In suburban environments, both overheadand underground routing is also commonplace, the latter particularly inthe case of new construction.

[0005] In urban environments, however, cable routing is a difficultfeat. Often, overhead routing lines are either non-existent, or arealready used to full capacity. Underground routing is exceptionallyexpensive, when available at all, since adding additional tunnels orconduit often involves tearing up lengthy expanses of street orpavement. Boring machines are generally not practical, as the subsurfaceis already laced with numerous tunnels, conduits, subways, water lines,sewer lines, gas lines, and the like. Thus, a cost-effective method ofrouting additional cables of any type in urban environments is verydesirable.

[0006] Use of existing infrastructure, for example water and sewerlines, particularly the latter, has been proposed. However, cable cannotmerely be introduced into such environments and left to freely move.Continuous movement over long periods can generate fatigue andwork-hardening in metal conductor-containing cables. Sudden movements orthe development of sharp bends or kinks can be destructive of fiberoptic cables. Moreover, despite the numerous advances in cableinsulation, covering, and armor, it is still not desirable, as a generalrule, that the cable be continually immersed in liquid. For thesereasons, it is desired to route, or “string” the cables in the topmostposition of the pipeline where exposure to liquids is minimized to theextent possible, and, if possible, to enclose the cable in protectiveconduit.

[0007] In order to accomplish these aims, several methods have beenproposed. In copending U.S. application Ser. No. 09/679,987 filed Oct.5, 2000, it is proposed to employ an otherwise conventional pipelinerelining procedure using a thermoplastic or thermosetting liner, thisliner also having integral cable conduit(s) as supplied, and asillustrated in FIG. 2. By this procedure, it is possible to supply oneor more cable conduits during the relining process. The conduits arefixed in position, and the conduit interiors are preferably isolatedfrom the liner interior, to prevent or minimize contact of cable withpipeline fluids. This method is very cost-effective where pipelinerenovation by relining is mandated. However, the method is notsatisfactory for pipelines which are not totally in need of renovation.

[0008] It has been proposed to install “J-hooks” in the ceiling of sewerlines, the J-hooks carrying conduit or cable, as disclosed in FIG. 1.Installation of the J-hooks is problematic, however. Each hook requiresdrilling a hole into the existing pipeline, and securing the J-hook withan expandable lead “anchor” or by using a cementitious or adhesivegrout. Due to the nature of sewer pipe material of construction and itsconstant exposure to wet or moist environments, many installationfailures are to be expected, as is also occasional damage to the pipeitself, including perforation, cracking, etc. Installation is a slowprocess. Moreover, due to little support in directions transverse to thestem of the J-hook stem, the hooks may be removed by occasional passageof obstructions down the pipe, or by collision with sewer cleaning orrenovating robots, etc.

[0009] It has been reported in the New York Times, Mar. 8, 2001, pp. G1and G7, that Ka-Te System A. G. has developed a robotic system forinstalling bands resembling hose clamps, these bands having clampsmounted thereon to mount conduit. However, the robotic system forexpanding the bands is complex and expensive, the bands provide littlelateral support, and thus are subject to cocking out of position. Due inpart to this lack of lateral support, bands must be installed closetogether in order to provide the necessary degree of support for theconduit.

[0010] It would be desirable to provide a method for routing cableswhich is cost-effective, which has little if any chance to damage thepipeline during installation, and which provides sufficient lateralsupport for the cable or conduit-receiving means that occasional passageof bulky materials or collision with pipeline cleaning equipment, etc.,will not cause failure of the support means. It would be furtherdesirable in preferred embodiments to provide a means of routing cablesand/or conduit through existing pipelines which does not requirepipeline relining, or the boring of numerous holes for discrete supporthooks or other devices.

SUMMARY OF THE INVENTION

[0011] The present invention is directed to a method of routing cablesand/or conduit through existing pipelines, preferably by means of aplurality of discontinuous coiled or folded, expandable sleeves whichare expanded and locked into place in an existing pipeline at regularintervals, or a plurality of discontinuous carriers of cylindricalsection, each sleeve or section containing or adapted to receive atleast one cable and/or conduit-receiving support means, and beingconfigured so as to resist lateral “cocking” or “canting” forces. Thepresent invention further pertains to a flexible support means suitablefor installation between a pipeline wall and a liner, when relining ofthe pipeline is indicated.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012]FIG. 1 illustrates a prior art process of routing cables and/orconduit in existing pipelines employing J-hooks;

[0013]FIG. 2 illustrates a prior art process of routing cables and/orconduit in existing pipelines by a pipe relining process;

[0014]FIG. 3 illustrates one embodiment of the present invention,employing a coiled sleeve of plastic material carrying a conduit supportmeans on its interior surface;

[0015]FIG. 4 illustrates another embodiment of the present invention,wherein the conduit support is on the exterior of an expandable sleeve;

[0016]FIG. 5 illustrates an embodiment of the subject invention wherethe conduit support forms part of the locking system of a coiled,expandable sleeve;

[0017]FIG. 6 illustrates a coiled metal sleeve having integral conduitsupport;

[0018]FIG. 7 illustrates another embodiment of a locking means which canbe employed with a variety of sleeves;

[0019]FIG. 8 illustrates a compressible foam or rubbery elastomerexterior covering which promotes maintenance of position in a pipeline;

[0020]FIG. 9 illustrates spring-type “fingers” of two types whichpromote maintenance of position in a pipeline;

[0021] FIGS. 10-13 illustrate various embodiments of cable supportmeans;

[0022]FIG. 14 illustrates one embodiment of a snap-in support means;

[0023]FIG. 15 illustrates a snap-in support means installed on acarrier;

[0024]FIG. 16 illustrates one embodiment of a thermoplasticcarrier/support means combination;

[0025]FIG. 17 illustrates one embodiment of a thermosettablecarrier/support means combination;

[0026]FIG. 18 illustrates one embodiment of a coiled metalcarrier/support means combination;

[0027]FIGS. 19a-d illustrates a further embodiment of a device of thepresent invention;

[0028]FIG. 20 illustrates a cross-section of a device of the typeillustrated by FIGS. 19a-d;

[0029]FIG. 21 illustrates one embodiment of a flexible support memberfor use in a pipeline in conjunction with a liner;

[0030]FIG. 22 depicts a flexible support member secured within apipeline by a liner;

[0031] FIGS. 23-29 illustrate various embodiments of multi-componentflexible support members;

[0032]FIG. 30 illustrates a preferred geometry of flexible supportmembers;

[0033]FIG. 31 illustrates a ribbed flexible support member; and

[0034]FIG. 32 illustrates flexible support members in the form offairings surrounding and supporting a conventional conduit.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0035] In the specification which follows, the term “cable structure”may be used to denote either a “cable” per se or a conduit forcontaining one or more “cables.” Individual “cable” types may be denotedas “wire cables” or “optical cables” as necessity dictates. The types ofwire cables and optical cables which may be routed employing the presentinvention are not limited. These may be electrical supply cables, i.e.for direct or alternating voltage for supply to households, businesses,machinery, etc., i.e. single, two, or multiple phase alternating currentof any voltage, generally 110 v to 440 v; low voltage wiring, especiallyfor control devices, for example 24 volt alternating or direct current.

[0036] Preferably, however, the “wire” cables are telecommunicationscables such as those customarily used in the telecommunicationsindustry. These may be of the coaxial type, single strands, sheathedcables containing a multiplicity of individual insulated strands ortwisted pairs, etc. Coaxial cables may be those commonly employed incable TV systems, i.e. those of 75 Ω impedance, or any other type.Multiple insulated wire cables may be those commonly employed inoverhead and underground telephone wiring.

[0037] Optical cables include those containing but a single fiber opticelement, as well as sheathed cables containing a plurality of fiberoptic elements.

[0038] The above examples of electrical cables, signal cables, andoptical cables are exemplary only, and not limiting. Any cable currentlyin use or yet to be developed may be routed using the subject devicesand method.

[0039] As is the case with electrical and optical cables, the type ofconduit of the “cable structure” is not limiting. These may be, forexample, iron pipe threaded at the ends for interconnection, steeltubing of the type generally called “emt,” plastic tubing, for exampleof polystyrene, polyvinyl chloride, polyethylene, polypropylene,polybutylene, or of other thermoplastic or thermoset polymers, flexiblemetal conduit, for example of the type known as “Greenfield,” sheathedflexible metal conduit, and the like. Conduit may be specificallydesigned for such operations as well, and may be routed as single tubes,as a bundle of individual tubes, optionally linked or brazed together orcoextruded, or as a sheathed set of multiple tubes. The conduit may besupplied as a continuous tube or as individual short lengths of tube.

[0040] The conduits may have, along the length thereof, or at theirtermini, “T” devices or elbows, etc., which allow signal cable from theinterior of the conduit to branch off, for example to enter a buildingor cross-street. To ensure water tightness, where such is desired, thecouplings, threaded ends, “T's,” elbows, and the like may be sealed withgrout, potting compounds, or the like, for example epoxy resins or RTVsilicones.

[0041] The conduit may also have bends, either gentle bends broughtabout only by stress against the conduit support means as the pipelinetraverses a gentle radius, or bends produced by bending the conduitprior to or after installation, for example by a tube bending device,etc.

[0042] The method of routing according to the subject invention involvesinstalling conduit support means, as described hereafter, along a lengthof pipeline, and stringing cable by means of the supports providedthereby. The support means may be located at any desired interval in thepipeline. For very rigid conduit, for example, a support every twenty orso feet may suffice. However, in most cases, even with relatively rigidand self-supporting conduit, intervals of 10 feet or less are generallyappropriate. The actual interval may be dictated by the system designerusing known principles of civil and mechanical engineering. Forstringing electrical, metal conductor, optical, and other signal cables,without conduit, more closely spaced intervals, e.g. every three to fourfeet may be desirable. The actual spacing is not critical to theinvention. In preferred embodiments herein, the method of routing one ormore support means are associated with each of a plurality of“carriers.”

[0043] The carriers of the subject invention are cylindrical sleeves orportions thereof which are installed, in their various configurations,either continuously, in the case of flexible cable support members, ordiscontinuously in the case of other embodiments. In discontinuousinstallation, a plurality of spaced apart carriers are installed in apipeline, at a spacing such that metal or polymer conduit may besufficiently supported.

[0044] In the case of the discontinuous coiled or folded structures asdefined herein, the unfolding of the structures is associated with ameans of locking the carriers in place without the use of robotic meansof turning threaded fasteners, etc. For example, the devices may beexpanded with a pneumatic or hydraulic expanding bladder or mechanicalexpanding means. For thermoset products, the expanded structure, nowbearing against the pipeline wall, is cured in place. In the case ofnon-curable polymer or metal sleeves, the sleeve-type carrierspreferably contain an autolocking feature which, upon expansion, lockthe sleeve in place. The aspect ratio (diameter/length) is sufficient,in the absence of adhesive, to prevent the carriers from cocking in thepipeline.

[0045] When the carrier is a longitudinal portion of a cylinder suppliedin continuous form as a flexible support, the flexible support isinserted into the pipeline between the pipeline wall and a conventionalthermoplastic or thermoset liner, and fixed in position as the liner ispressed against the pipeline wall and, in the case of thermoset liners,cured in place.

[0046] The carriers for the support means are generally of cylindricalsection, whose outside diameter preferably provides, followinginstallation, a tight fit against the pipeline interior wall. In a lesspreferred embodiment, the carriers may be of somewhat lesser diameterthan the pipeline, and held into position by adhesive grout. However, itis anticipated that carriers of this nature will, in most cases, be moretime consuming to install. Carriers which fix themselves into positionupon uncoiling or expanding are preferred. Such carriers may be placedinto position without any adhesive grout, which is the most desirablefrom a time and economy standpoint. Alternatively, such carriers may fixthemselves into position and may then be adhesively bonded to thepipeline wall, either by an adhesive located on the outside of thecarrier, or by an adhesive grout injected between the carrier and thepipeline wall following positioning of the carrier. In such cases, theincrease in stability towards unwanted movement secured by the adhesivemay outweigh any increase in cost or complexity, especially when heavyconduit is to be routed. However, because the carrier is fixed stablyinto position before adhesive is cured, or in some cases, beforeadhesive is applied, installation time is still minimal and economy isnot overly affected.

[0047] The carriers bear, or are adapted to receive, at least one cablesupport means, i.e. a physical device capable of supporting one or morecable structures. The cable support means may take numerous forms, solong as the support means is capable of supporting or encompassing thecable to the degree necessary for a secure installation. For example,the support means may comprise a ring, hook, tube, bolt, flange, etc.Other embodiments of support means will readily suggest themselves tothose skilled in the art. Some of the more preferred support means maybe described in relation to FIGS. 10-13. FIG. 10 illustrates oneembodiment of a generally u-shaped support means 101 with a u-shapedchannel 103 adapted to receive one or more cables, and one or twoflanges 105 (two are shown), which may be spot welded, riveted, boltedor otherwise fastened to the carrier. Adhesive bonding to the carriermay also be used, as may also a variety of locking means, preferablyspring loaded locking means. Support means such as those of FIG. 10 maybe supplied, for example, with a curable pressure sensitive adhesivesurmounted with a peelable release film. The adhesive may be cured byheat, by moisture, or by application of a curing agent or curingaccelerator.

[0048] In FIGS. 11a and 11 b are shown a generally u-shaped (circular,elliptical, square, rectangular, etc. cross-sections are also possible)support means 111 which is located in and is integral with the wall ofcarrier 113, and is formed therein by punching, or by cutting two ormore parallel slits and bending the portion enclosed by the slitsinwards.

[0049]FIGS. 12a and 12 b illustrate a further embodiment, similar to thesupport means of FIG. 11, wherein the portion of the carrier wall 121punched out forms a hook 123 rather than a u-shaped structure. As can beseen from FIGS. 11 and 12, the actual shape of the support means isunimportant, so long as it serves its function of supporting the cablestructure to be routed. It should be noted that a support means carriersuch as those of FIGS. 11 and 12 may be manufactured with multiplesupport means rather than a single support means.

[0050]FIGS. 13 and 13a illustrate a very useful embodiment, where thecarrier 131 has several projecting support means receiving flanges 133stamped into the carrier 131. These flanges may be essentiallytriangular, as shown in the locking means of FIG. 4 of U.S. Pat. No.5,351,720, or may take the form of bent tabs as in FIG. 13b herein. InFIG. 14, the support means 141 has projections, or as shown, flanges143, and may be made of a resilient material, preferably stainlesssteel, more preferably a stainless steel having spring characteristics,or a fiber reinforced thermoplastic or thermoset polymer. As shown inFIG. 14b, the support means 141 may have projections 145 adapted to mateparticularly with the receiving flanges. In the case of receivingflanges such as those of 133 in FIG. 13, such projections may assist inpreventing lateral movement of the support means. In FIG. 14c, thesupport means 141 is of rectangular section with associated flanges,while the support means of FIG. 14d has no flanges, but only projections145. Other variations, as well as means of preventing lateral movement,e.g. stop flanges in the wall of the carrier readily suggest themselvesto one skilled in the art.

[0051] The support means of the types illustrated by (but not limitedby) FIG. 14 are compressed slightly, for example by applying pressure onthe flanges, and snapped into position into the receiving flanges shownin FIGS. 13, 13a and 13 b or in equivalent receiving structures. Theresult is an installed support means as shown in FIGS. 15 and 15a, withthe flange 143 of the support means 141 being locked into receivingflanges 133 in the wall of carrier 131.

[0052] The “snap-installed” or “locking” support means described inFIGS. 13-15 have several notable advantages. First, they may beinstalled in the field, if desired. Second, the shape and size of thecable-receiving portion of the support means may be varied to suitdifferent sizes and numbers of cables. Third, the carrier may bemanufactured with numerous receiving flanges so that a plurality ofsupport means may be installed, either at the same or at differenttimes. Thus, the method of the subject invention anticipates thenecessity of further cable routing as communication, etc. demandsincrease in the future. Fourth, a series of staggered receiving flangesmay be provided in order to supply a straight path for cable wheninstallation of the carrier is inadvertently displaced radially in thepipeline. Fifth, the snap-installation support means may be easilyun-installed, should that be necessary, or replaced with differentlyshaped support means.

[0053] In addition to the support means described above, the supportmeans may be bolted to the carrier, may be bonded by pressure sensitiveadhesives, epoxy resins, silicone adhesives, polyurethane adhesives, andthe like. Any means of fastening, mounting, or forming the support meansonto or into the carrier may be used. These methods of mounting,forming, etc., and equivalents thereof are well known to those skilledin the arts of forming materials and fastening materials.

[0054] The carrier of the present invention may take numerous forms.Essentially, the carrier is a tubular, or “cylindrical” structure orportion thereof which can be inserted and transported into the pipelineand fixed into place, preferably without boring holes into the pipelineor, in general, without piercing the wall of the pipeline by any means.Thus drilling or purposeful piercing operations are generallyunnecessary in preferred embodiments. However, it would not depart fromthe spirit of the invention to install a carrier by one or more of themethods disclosed herein, following which a spike, nail, bolt, anchor,etc. may be installed in the pipeline wall as a redundant securingmeans. Moreover, in one less preferred aspect of the invention, a“holed” fastener may be used to secure, preferably temporarily, acarrier which is adhesively bonded or grouted to a pipeline wall untilthe adhesive bond is cured to the extent necessary to join the carrierto the pipeline wall. In such cases, the weakening of the pipeline wallwhich is disadvantageous with prior art “J-hooks” is overcome, as theinstalled fastener is surrounded by adhesive or grout, and the pipelinewall in the vicinity of the fastener is reinforced by the presence ofthe carrier.

[0055] Several embodiments of carriers will be discussed hereafter;others will readily suggest themselves to those skilled in the art. In afirst embodiment, the carrier is an expandable thermoplastic orthermoset tubular sleeve. In these embodiments, the sleeve is insertedinto the pipeline in a folded configuration such as those shown in FIGS.16 and 17. In FIG. 16, the carrier is a thermoplastic sleeve 1601 whichcarriers a preformed support means 1603 preferably of the same type ofthermoplastic. Such carriers and support means may be manufactured byconventional extrusion techniques and sliced into suitable lengths. Suchproducts are, before slicing into short lengths, substantially the sameas the integral liner/conduit assemblies of copending U.S. applicationSer. No. 09/679,987, and may be made in a non-limiting sense, of similarmaterials, e.g. polyolefins, polyvinylchloride, and the like. Thetubular sleeve length may be any length sufficient to provide resistanceto “cocking” in the pipeline.

[0056] For example, but not by way of limitation, the length may be fromabout one third the pipeline diameter to about three times the pipelinediameter, more preferably about one half the pipeline diameter to aboutone and one half times the diameter for pipelines less than about 12inches diameter. For larger pipelines, the carriers may have a somewhatnarrower aspect than those used in smaller pipelines. For example, forpipelines having diameters of 1 to 2 feet, the minimum length shouldrange from about 4 inches for 1 foot diameter pipelines to about 6inches for 2 foot diameter pipelines; for pipelines between 2 and 4 feetin diameter, the minimum carrier length should range from about 6 inchesfor a two foot diameter pipeline, about 8.5 inches for a three footdiameter pipeline, and about 10 inches for a four foot diameterpipeline. These minimum lengths are all preferred minimum lengths,suggested for use in the absence of grout and in the absence of loadingmeans as hereafter described, in order to form a carrier resistant tococking in the pipeline.

[0057] The preferred maximum lengths also vary with the pipelinediameter, but again not directly. Carriers for smaller pipelines ingeneral, are preferably longer in relation to the pipeline diameter thanin larger pipelines, partially because longer lengths in small diametersare economically feasible. Thus, the preferred maximum length in a 1foot diameter pipeline ranges from 0.75 feet to 1.5 feet, while in a 3foot pipeline, it may range from 1.5 feet to 3 feet. Longer lengths willbe essentially wasteful of material. Moreover, routing cable will beincreasingly more difficult the longer the sleeve. This defect can beeliminated in part by removing portions of the support means so that itis shorter than the sleeve proper. In no case will the sleeve be so longas to constitute a relining operation as that operation is understood byone skilled in the art of pipeline relining, i.e. the installation ofsuch sleeves is “discontinuous”.

[0058] In FIG. 16, the sleeve is shown folded into a “C” section. Othertypes of folding are useful also, as shown in U.S. application Ser. No.09/679,987. In FIG. 16, the support means is shown surrounding anoptional “collar” or bushing 1605 which may comprise a metal tube,thermoset polymer tube, high melting point thermoplastic tube, ceramictube, etc. The function of this bushing is primarily to avoid collapseof the thermoplastic support means 1603 when the carrier is heated andexpanded into the pipeline. The bushing may be equipped with smoothed oroutwardly flared ends to facilitate entry of cable through the bushing.The bushing may, if not made of a lubricious material, be coated with alubricious substance or may contain an inner sleeve of lubriciouspolymer, i.e. PTFE, polyethylene, or polypropylene, or a natural orsynthetic wax, grease, or the like. More than one support means may bemolded into the same sleeve. In addition, the sleeve may be modified toaccept snap-in support means. A plain circular folded expandable sleevenot bearing any support means when manufactured, but manufactured tocontain fastening devices, receiving flanges for snap-in support means,or adhesively bonded, fusion bonded, solvent bonded, etc. support means,may be used as a carrier.

[0059] In practice, the expandable thermoplastic carrier is insertedinto the pipeline, and heated, before, during or both before and duringinstallation, to a deformable state. Pressure, for example an inflatabletubular bladder, is applied from within the folded sleeve, unfolding itand pressing it against the interior wall of the pipeline. Theexpandable or inflatable bladder may be equipped with heating means,such as an internal bladder or path for hot water, steam, etc., or maybe equipped with an electrical heating device. Adhesive may be locatedon the outside of the carrier, applied to the pipeline wall, or injectedbetween the carrier and the wall to insure positional stability.Adhesive is particularly useful with carriers whose length isappreciably less than the pipeline diameter, for example one half to onethird the pipeline diameter. Thus, sleeves with lengths of one to twoinches in 10 inch to 12 inch pipelines may require an adhesive to keepthem stably positioned during cable routing and subsequent use of thepipeline.

[0060] In another embodiment, the carriers may be curableresin-impregnated woven or non-woven sleeves, also generally in a foldedconfiguration, for example a short section of the integralconduit/reliner of copending Application U.S. Ser. No. 09/679,987, asillustrated in FIG. 17. Such short lengths may contain one or aplurality of support means. In the case of curable resin-impregnatedcarriers, it is very preferable that the support means be rigid or carrya rigid collar or bushing, as described as an option for thermoplasticfolded, expandable carriers.

[0061] In thermoplastic carriers/support means, the generally high wallthickness of the thermoplastic carrier combined with the small relativesize of the cable support means will often allow insertion and expansionof the carrier without substantially deforming the support means. Thecable receiving hole in the support means is generally supplied in alarger diameter than the diameter of cable to accommodate somedeformation. An elliptical or elongated circular cross-section with themajor axis directed radially toward the center of the pipeline may alsobe quite advantageous. Upon expansion, this elongated cross-sectionsupport means will be expected to distort somewhat, toward a morecircular cross-section.

[0062] However, in the case of resin-impregnated fibrous carriers, thecarrier and any support means portion made of the same material hassubstantially no rigidity until cure. Thus, if there is no rigid collaror bushing, alternative means will have to be used to maintain the shapeof the cable-receiving hole of the support means until after cure. Forexample, a removable plug may be used for this purpose, or pressure maybe applied to the interior of the cable-receiving hole. However, thelatter is technically difficult. Thus, solid or inflatable plugs (i.e.balloons) should be used in the cable-receiving holes during expansionand cure if rigid collars or bushings are not used.

[0063] The resin of the resin-impregnated sleeves may be moisturecurable, anaerobic curing (when applicable), thermosetting (i.e. epoxy,bismaleimide, RTV silicone, etc.), or photocurable, i.e. photocurableunsaturated polyester. All such resins are well known in the art.Photocurable resins are preferred. Examples of suitable resins may befound in U.S. Pat. Nos. 2,944,994, 4,581,247, 4,439,469, and 4,135,958.

[0064] A resin-impregnated fibrous sleeve is depicted by FIG. 17, wherethe carrier 1701 bears support means 1703 which, in this case, is itselfa resin-impregnated fibrous structure, i.e. resin-impregnated woven ornon-woven fiberglass, synthetic fiber, needled felt, etc., as is themajor portion of the carrier 1705. The support means includes a rigidcollar or bushing 1707.

[0065] In a preferred embodiment, the carriers take the form of anexpandable, coiled structure. In this embodiment, the carrier is acoiled, cylindrical structure whose outermost diameter, because of thecoiling, is sufficiently less than the inside diameter of the pipelineto allow it to be inserted and positioned prior to expansion byuncoiling and locking into a fixed position. The carrier may or may notcarry cable support means prior to introduction into the pipeline;support means or additional support means may be added followinginsertion. By the term “cylindrical” is meant the shape followinginstallation. The structure, prior to coiling, may be viewed as acylinder split to have a seam defining two lateral edges. The split neednot be parallel to the pipeline direction, but may be at an angle, i.e.a spiral slit, so long as the ends may pass by each other to form acoiled configuration. In a preferred embodiment, simple expansion of thecoil by a pneumatic or hydraulic bladder serves to allow the carrier tolock in its expanded condition.

[0066] In coiled or folded versions of the carriers disclosed herein, bythe “exterior” or “external surface” and like terms is meant thatsurface of the device which will be located adjacent or proximate theinterior wall of the pipeline in which the carrier is to be installed,while the “interior” or “internal surface” or like terms means thesurface remote from the pipeline interior wall, which will form a newinterior surface in the pipeline through which the fluid carried by thepipeline may flow. In similar fashion, the “interior” or “internalsurface” of a cable structure support means will be the surface closestto the cable or conduit to be installed in the cable support means. By“lateral edge” or like terms with respect to coiled carriers is meantthe edges of the coiled structure which will change their positionduring expansion of the coiled cylindrical sleeve into a lockedcylinder. In sleeves where the lateral edge is orthogonal to theimaginary face of a (closed) cylinder, i.e. parallel to the length ofthe cylinder, these lateral edges will also be parallel to the directionof the pipeline. By “ends” with respect to the sleeve is meant the endsperpendicular to the axis of the cylinder and at the extremes thereof.

[0067] One embodiment of a coiled carrier is shown in FIGS. 3a and 3 b.In FIG. 3a, the coiled carrier 31 (in cross-section) is of plasticsmaterial, and carries support means 33. At end 35 of the carrier, thelateral edge is manufactured with a notch, while the opposite lateraledge 37 is manufactured with a corresponding apex or tongue to mate withthe notch. The exterior of the carrier may optionally be coated with orlaminated to a foraminous or solid elastomeric material 39. The carrieris shown from the side, installed in a pipeline 34 in FIG. 3b, where thewalls 36 of the coiled carrier are surrounded by elastomer or adhesive39. Suitable edge-type locking means are shown in U.S. Pat. No.5,725,026, herein incorporated by reference. Alternative edge-lockingmeans are illustrated, for example, in U.S. Pat. Nos. 5,351,720;5,971,030; 5,119,862; and 6,138,718; the disclosures of which areincorporated herein by reference. The exterior may also be coated withadhesive. In preferred cases, the adhesive is a curable gel or softelastomer which can then take place of the foraminous or elastomericcoating 39.

[0068] In use, the coiled structure is inserted into the pipeline,positioned longitudinally and radially (to line up support means, etc.)and expanded by an elastomeric bladder or other device, i.e. a rubberybladder expanded by air, water, or other fluid pressure. Suitableexpansion means are known to the art; several are disclosed in thepatents previously mentioned, for example. The expansion must initiallybe enough to force the locking edges of the coiled structure pastthemselves, so that they may lock when the pressure is released.

[0069] Due to the relatively small tolerances which would otherwise berequired, it is preferred that the assembly include an elastomeric orforaminous covering, a very viscous, thixotropic mastic-like adhesive oran elastomer or gel 39. The use of these allows the actual carrier 31 tobe made somewhat smaller than the pipe upon full expansion, theinterstice between the pipeline interior and the carrier exterior beingoccupied, at least in part, by a yielding and possibly somewhatdisplaceable elastomer, gel, etc. By this means, expansion such that thelongitudinally-oriented lateral locking edges pass each other and lockupon removal of internal pressure (i.e. bladder pressure) is more easilyachieved.

[0070] The foraminous or elastomeric coating may be any conventionallyknown, including those disclosed in U.S. Pat. Nos. 5,351,720; 5,971,030;and 6,138,718. For example, polypropylene foams, polyurethane foams,microcellular polyurethane elastomers, non-cellular polyurethaneelastomers, natural rubber or synthetic rubber, i.e. buna-N, neoprene,chloroprene, etc., may be used. Heavily loaded (filled) curableadhesives of any type may be used. Such adhesives are well known andreadily available commercially. Likewise, numerous RTV siliconeelastomeric adhesives may be used, as well as epoxy adhesives. It isdesirable that such adhesives be one-component adhesives, i.e. RTV-1type adhesives. Moisture curing adhesives are most preferred, such asmoisture curing RTV-1 silicone adhesives.

[0071] In FIG. 4, a carrier is shown which is similar to that of FIG. 3,but the support means is located on the exterior of the coiled carrier.Upon installation, the installed carrier 401 and support means 403 isshown inside pipeline 405. The locking ends 407 and 409 are locked. Notethat there is a bulge as a result of this type of installation, althoughthe tolerances required are less.

[0072] A further form of coiled, expandable carriers, which arepresently preferred over the coiled plastics carriers just described,comprise coiled metal carriers with a locking feature. The lockingfeature may be any mechanical contrivance which functions to lock thecarrier in an expanded condition. Many types of locking devices are thuspossible. Several examples of locking devices are illustrated in FIG.13. Preferred locking devices are “autolocking” passive devices whichlock upon expansion of the coiled structure, without the need forspecial mechanical devices to manipulate closures such as those found onhose clamps and the like.

[0073] A further suitable carrier is similar to the repair sleevedisclosed in U.S. Pat. No. 5,351,720, and illustrated by FIG. 6 herein.In FIG. 6, the carrier 61 of the invention is shown in its uncoiledexpanded and locked position. For the sake of simplicity ofillustration, only the carrier is shown in FIG. 6, no grout orelastomeric covering being located on the outer surface 62 of the sleeve61. At each end portion of the carrier 61 is an outwardly projectingflare 63, including an outer flare surface 64 which generally providesan extension of the outer surface 62 of the carrier. Although the angleof the flares or flare portions 63 relative to the outer surface 62 ofthe carrier is shown to be approximately 45°, other angles can beutilized and still enable the sleeve to meet the objectives furtherdescribed below. Notches 65 have received corresponding lockingprojections to lock the carrier to lock the edges 66 and 67 together.Bands 68 may, if elastomeric, assist in maintaining a coiledconfiguration prior to expansion and locking. They may also serve tolimit the spreading of injected grout between the carrier and the pipe,when grout injection is desired. A conduit support means is shown at 69.Multiple support means may be installed.

[0074] A significantly improved version of the device of FIG. 6 has thetabs on one of the two flared end portions 63 bent at an acute anglesuch that rather than extend away from the generally tubular sleeve 62,they are bent back over the sleeve as shown in FIG. 6a. Such devices aremore readily inserted into a pipeline as both sets of tabs are orientedin the same direction.

[0075] It is preferred, particularly with metal carriers of limitedaspect ratio, but also with polymer-based carriers of thermoplastic orof previously cured thermosetting, fiber reinforced polymer, that theexterior of the carrier be loaded radially inwards by a carrier “loadingmeans” which functions to exert a force between the pipeline interiorwall and the exterior of the carrier. The loading means may be a seriesof radially outwardly directed flanges as shown in FIG. 6, may bespring-like fingers as shown in FIG. 9, or may take other forms,preferably as a result of bending, cutting, or punching operations onthe metal carrier, or in the case of previously cured thermosetcarriers, during the curing operation.

[0076] Alternatively, the loading means may comprise an elastomeric,deformable cover or band covering the exterior of the carrier or aportion thereof when installed. The outer diameter of thelocked-in-place carrier is selected, relative to the pipeline insidediameter, along with the thickness of the elastomer, to place the latterunder compression, thus exerting a force or “load” between the pipelinewall and the carrier.

[0077] Loading means such as those described, or others which functionto radially load at least a portion of the carrier in a direction inwardfrom the pipeline interior wall are most important, and preferablyrequired, in the absence of grout, for aspect ratios less than 0.2.However, these carrier loading means are also desirable with largeraspect ratios less than 0.33, and even when the aspect ratio is quitelarge, i.e. 1.2 to 1.5 or greater. In addition to performing thefunction of radially loading the carrier to aid in preventing itsdisplacement from the desired installed position, the carrier loadingmeans enables easy installation which can be accomplished with verysimple robotic devices, i.e. those having a simple expandable bladderfor expansion and locking of the carrier in the pipeline.

[0078] For example, a carrier may be prepared as shown generally in FIG.6, with a single set of locking projections, but with several sets oflocking notches, in rows parallel to the lateral edge of the device.Upon expansion against the loading means, the locking projections willfirst pass the set of locking notches which would result in a minimumdiameter carrier. As the carrier is more fully expanded against thepressure of the loading means, a second set of locking notches will havebeen passed. Upon release of the pressure of expansion, the loadingmeans will attempt to force the coil into a smaller diameter, whereuponthe locking projections will enter and mate with the last set of lockingnotches passed, thus locking the carrier into position. The forceexerted by the expanding means, i.e. a bladder, can be adjusted to takeaccount of variations of actual diameter, i.e. caused by pipelinemanufacturing tolerances, wear, or the presence of deposits. The forcemay also be mitigated for older pipelines which may not be as robust asnewer pipelines. Of course, the loading means described above may alsobe used with grout or adhesive.

[0079] A further embodiment of the subject invention is shown in FIG.18. In FIG. 18, the carrier 1801 is a tubular sleeve having a lip 1803along one edge and an edge receiving flange 1805 attached to theopposite edge 1807 of the carrier. At one portion of the periphery ofthe carrier, a cable support means, in the form of a generallysemicircular or U-shaped trough 1809 is punched into the carrier. Thecarrier may be extruded with the trough already formed, or the troughmay be added subsequently, particularly in the case of metal carriers.The trough 1809 may extend all along the length of the carrier, i.e. tothe opposite end 1811, or may extend only along a portion of the length.In FIG. 18, two troughs 1809 and 1813 are illustrated, with a portion ofthe carrier 1815 being continuous, i.e. not having a trough.Alternatively, the trough may be located in the middle of the device,where portion 1815 is now located, with the end portions of the carrierbeing continuous between the longitudinal edges of the device. More thanone support means may be provided, i.e. a plurality of troughs or seriesof troughs may be formed radially around the carrier. A cross-section ofa carrier with two support means is shown in FIG. 18b.

[0080] The device of FIG. 18 has several notable advantages. First, thedevice is easily and economically manufactured. Second, particularlywhen U-shaped troughs are employed, the U-shape adds an additional areaof flexion as shown in FIG. 18b in an enlarged view where the U-shapehas been distorted somewhat as the coiled carrier is expanded. Theability of the support means to distort in this fashion may assist inenabling the locking edges to slide by each other as the device isuncoiled to enable the locking mechanism to engage, and yet followinglocking of the edges, when the U-shaped support means return to theirundistorted shape, allow the outside diameter of the now-locked carrierto correspond closely with the inside diameter of the pipeline intowhich the carrier is inserted. Deep U-shaped troughs facilitate suchspring-like movement, whereas more semi-circular troughs are not asspring-like. As with other embodiments, the device of FIG. 18 may havean elastomer, elastomer foam, adhesive, grout, etc. mounted on theoutside surface, preferably with the exception in the vicinity of thetrough, or may have adhesive grout, etc. applied between the outsidewall of the device and the inside wall of the pipeline.

[0081] The length/diameter (“aspect ratio”) of coiled metal carriersinstalled without the addition of adhesive or grout located between thecarrier and the pipeline wall should be such that the carrier does not“cock” or “cant” out of position in the pipeline when exposed to lateralforces. For this condition, the carrier should preferably have a minimumaspect ratio of at least 0.25 for pipelines up to 2 feet in diameter,more preferably at least 0.33, yet more preferably at least 0.5, andmost preferably at least 0.75. For pipelines greater than 3 feet indiameter, the minimum aspect ratio is preferably greater than 0.2, morepreferably greater than 0.25, yet more preferably greater than 0.33, andmost preferably greater than 0.5.

[0082] In metal carriers such as the above, the greater the aspectratio, the more resistant will be the carrier to being cocked ordisplaced in the pipeline. Thus, aspect ratios of 0.75 to 1.5 arepreferred for carriers for smaller pipelines, whereas aspect ratios of0.6 to 1.0-1.2 are preferred for larger pipelines. Aspect ratios may goas high as 2.0 or higher, but aspect ratios higher than 2.0 are notpreferred.

[0083] In the case of carriers having elastomeric material on theexterior, the aspect ratio may be lowered, as compression of theelastomer will generate a force which will tend to resist locking in thepipeline. In such cases, smaller diameter carriers may have aspectratios as low as 0.2 or lower, while larger diameter carriers may haveaspect ratios as low as 0.15. These aspect ratios are suitable forgrouted carriers as well.

[0084] In another embodiment, the carrier is in the form of a section ofa hollow cylinder whose outside radius of curvature correspondssubstantially to the internal pipeline radius. Such a device is shown inFIG. 19, and may be made of metal or plastic. Referring to FIGS. 19a and19 b, the device 1901 comprises carrier 1903 whose outside radius ofcurvature R in some embodiments, is substantially the same or preferablysomewhat less than the radius of curvature R′ of the inside of pipeline1913. The carrier 1903 carries cable support means 1905 containing ahole 1907 or channel 1909 (FIG. 19c) to receive the cable. The carrier1903 may be directly mounted to the inside of pipeline 1913 by means ofone or more fasteners (screws, nails, bolts, spikes, etc.) 1911 whichare inserted through holes 1915 optionally provided. This method ofattachment is less preferred.

[0085] A more preferred mode of attachment is shown in FIG. 19b. In thismode, the outside radius R is preferably, but not mandatorily madeslightly less than the interior pipeline radius R′ so that a layer ofmastic or adhesive 1917, i.e. an epoxy or urethane gout, etc., maysomewhat uniformly fill the space defined between R and R′. In oneembodiment of this mode of attachment, the fastening devices 1911 arestill used. However, these devices fulfil only a portion of thenecessary adherence to the pipeline, the remainder formed by the curingof the adhesive. In a more preferred embodiment of this mode ofattachment, only a few, or preferably only one fastener 1911 is used.Such a fastener is advantageously located at the center of curvature ofthe device, as shown in the channel support means device of FIGS. 19cand 19 d. In such cases, it may be desirable that R be slightly greaterthan R′ such that the distortion of the device upon tightening thefastener will apply pressure between a substantial part or all of theoutside surface of the carrier and the pipeline wall. In the case ofcarriers having enclosed support means 1907 as shown in FIG. 19a, aportion of the central portion of the support means, i.e. at a locationhalfway down the length of the device, may be machined away to form afastener access hole 1923 (or the part may be molded with the holealready in place) so that access to the fastener hole 1921 may beprovided. A cross-section across 20-20 is shown in FIG. 20. This devicehas an optional shoulder 1925 machined or molded in to received the headof the fastener, so that it does not protrude into the cable supportmeans cavity 1907.

[0086] A further preferred means of attachment is adhesive bonding ofthe carrier to the pipeline wall by means of adhesive without the use ofany fastener. In such cases, either a fast setting adhesive ispreferred, or the carriers are preferably installed from the mostdistant locations first, leaving an expanded balloon or bladder in thepipe temporarily until adhesive is set. In all these adhesiveapplications, whether fasteners are also used or not, it is preferableto first clean the pipeline wall by standard means to encourage firmbonding. This is true of other embodiments herein where adhesives areused as well, although in completely circular embodiments, i.e. such asthose illustrated by FIGS. 3 to 6, this is less important, as theadhesive does not form a large part of the attachment of the device andneed accept much lower loadings.

[0087] A principle advantage of the embodiment of FIG. 19 wherefasteners only are used, as compared to devices such as J-hooks, is thatthe relatively large surface area helps to distribute loads which, ifapplied to a single unsupported fastener, would result in bending orbreaking of the fastener or the portion of the pipeline wall in which itis anchored.

[0088] In the embodiments of FIG. 19 which employ both fasteners andadhesives, yet further advantages accrue. The adhesive takes much of theload which would otherwise be borne by the fasteners, particularlytransverse loads generally parallel to the length of the pipeline.Moreover, the presence of the carrier and adhesive surrounding thegeneral vicinity of the fasteners helps prevent deterioration of thepipeline wall at these points. For example, the adhesive will assist inboth preventing propagation of cracks formed by fastener insertion orsubsequent loading, and may assist in filling these cracks as well.

[0089] The above embodiments may all be modified to correspond to uniqueproblems associated with any particular installation. Moreover, thevarious individual features of the embodiments described are not usefulmerely with those figures illustrating those embodiments alone, but aregenerally useful with other embodiments in various combinations, aswell. As but one example, the snap-in support means of FIGS. 13 and 14can be used with a suitably designed fastener or adhesively bondedcarrier of FIG. 19.

[0090] In a further embodiment of the present invention, the cablesupport means comprises a “flexible” cable support whose preferablecross-section may be roughly described as a crescent shape. Such cablesupport means, more fully described hereinafter, are generally installedin a continuous fashion, in conjunction with a structural liner. Becausethe flexible cable support means include a conduit passage, the use ofseparate conduits is ordinarily unnecessary. However, in instances whereconduit is also installed, the type of conduit is not limited.

[0091] This embodiment of flexible cable support means of the presentinvention thus preferably comprises a generally crescent shaped elongatemember or combinations of members, as described hereafter. The flexiblecable support means is preferred to be a substantially continuousstructure, generally supplied as a large coil, or on a reel. Thiselongate member is inserted into an existing pipeline through a manhole,service connection, etc. Following insertion of the flexible supportmeans, a structural liner, preferably of the thermoset type, is insertedexpanded, and cured. The flexible support means is thus fixed into placebetween the interior wall of the existing pipeline and the exterior wallof the liner.

[0092] In its most preferred form, the flexible support means comprisesa unitary extrusion, as shown in FIG. 21 and more fully describedhereafter. However, the flexible support means may also be supplied astwo or more extrusions which are introduced into the pipeline togetheror individually, and positioned substantially adjacent each other. Aflexible support means is shown installed in a relined pipeline betweenthe pipeline interior wall and an installed liner in FIG. 22.

[0093] The flexible support means may be made of any material which issufficiently flexible or which can be rendered sufficiently flexible tobe able to enter and traverse the pipeline, preferably through existingopenings such as manholes, cleanouts, etc. Thus, the flexible supportmeans may be made of a rubbery elastomer which is flexible at ordinarytemperatures, or a thermoplastic material which is rigid at ordinarytemperatures but becomes flexible at reasonably elevated temperatures,for example, but not by limitation, temperatures in the range of 60 to150° C., more preferably, 80 to 120° C. Preferable materials ofconstruction include thermoplastics such as homo and copolymers ofpolyethylene, polypropylene, polyvinylchloride, poly(butadiene-styrene),polyamide, and the like. The flexible support material may also be madeof a thermosettable polymer, for example one which containsmoisture-curable, photo-curable, or elevated temperature thermocurablecrosslinking groups which transform the member from a quite flexiblepre-cure state to a less flexible and preferably rigid cured state. Incertain cases, the flexible cable support means may be made of aflexible metal such as aluminum, steel, stainless steel, brass, bronze,etc.

[0094] While the flexible cable support member may have numerouscross-sectional shapes, it is preferred that the flexible cable supportmember be of a crescent shape, preferably a crescent such that the radiiof the edge portions is less than the radius of the central portion, asdescribed more fully below. The advantages to the crescent shape areseveral. First, following installation of the structural liner, thepipeline interior will have a shape only modestly removed from circular,facilitating cleaning and any subsequent renovation operations. Second,and importantly, the crescent shape, particularly when prepared withvarying radii as described hereafter, will assist in distributing theload on the exterior of the pipeline to the structural liner, resultingin a structure far less subject to failure.

[0095] Certain advantages accrue when the flexible cable supportstructure is manufactured as a series of extrusions, as shown in FIG.23. In FIG. 23, the two “wings” or “fairings” 2341, may be made asseparate extrusions, in this case containing conduit passage 2342 and anadditional hollow portion 2343, predominately for economy in use ofmaterial and to aid flexibility, although in some instances this hollowcould also contain cable. The interior edge 2344 is configured withdovetail tongue 2345.

[0096] The central portions 2346 may be made in a variety of widths toaccommodate, for example, 1, 2, or 3 or more conduit passages 2342,which may be of the same or different size, and may be round incross-section, as shown, elliptical, square, rectangular, etc. At theedges 2347 of the central portion 2346, are located dovetail grooves orslots.

[0097] One or more central portions 2346 and one or more wing portions2341 may be snapped together above ground prior to entry into thepipeline. The ability of the sections to slide somewhat along the edgeportions aids in flexibility of the device. Alternatively, the sectionsmay be inserted separately into the pipe and locked together afterinstallation, or following the sharpest bend which will have to betraversed during installation. For example, just following the bend inthe pipeline, the separate sections may be introduced into a mandrelwith a crescent shaped hole which tapers from a larger hole to the sizeof the assembled flexible cable support member, forcing the dovetailstogether as they are pulled and/or pushed through the mandrel. Theassembled flexible cable support member may appear as in FIG. 24 withtwo wings 2341 mating with central portion 2346. In FIG. 25, two centralportions 2346 are linked together by a fastener 2348 which may be acontinuous strip, or as shown, may be separate fasteners installed atintervals.

[0098] In lieu of dovetails, other mating structures may be used asshown in FIGS. 26 and 27, for example a series of holes or slots 2661,with discontinuous fasteners 2662 which extend into mating holes onadjacent edges of central portion(s) and wings, or a continuous tongueand groove shown in FIG. 27, mating portions 2641 and 2646. In the caseof such structures, it may be prudent to apply an adhesive duringassembly to assist in keeping the various portions together. Adhesivemay be used with dovetail joints as well. For example, the edges may beflush as shown in FIG. 28 and preferably adhesively bonded, orcross-dovetails 2665 may be used to hold the sections together, as shownin FIG. 29, by insertion into mating slots 2666 in the side of thedevices. Other equivalent structures, device, and methods of attachingthe individual sections to each other will be apparent to those skilledin the art.

[0099] Following insertion of the flexible cable support member, astructural liner is inserted. The structural liner may be athermoplastic liner which is generally inserted in a foldedconfiguration and unfolded and expanded with hot water or steam, or maybe of the thermoset type, i.e. a moisture curable, thermally curable, orphotocurable liner. Examples of thermoset liners include liners offibrous reinforcement impregnated with unsaturated polyester resin,epoxy resin, and the like. Suitable resins are well known to thoseskilled in the art, and may be found in U.S. Pat. Nos. 2,944,994;4,581,247; 4,439,469, and 4,135,958, which are referred to herein.

[0100] In the most preferred method, the liner is everted, as is wellknown in the art, since by utilizing eversion, a simple robotic devicemay precede the liner and maintain the flexible cable support member inthe proper position until the positioning of the liner secures themember in place. Of course, conventional methods of locating theflexible support member, such as pins, bolts, screws, mastic, adhesive,grout, etc., may also be used. By using an everting-type liner, arobotic device or work crew may precede the liner to make taps intovarious buildings, connecting pipelines, etc.

[0101] A preferred method of cable routing employs the flexible cablesupport member of FIGS. 21 and 22. In this method according to theinvention, a flexible cable support member is installed in a continuousfashion in an existing pipeline, and maintaining in position as well asisolated from the pipeline contents by a structural liner, as shown incross-section in FIG. 22. A section of a preferred flexible cablesupport member is shown in FIG. 21. The flexible support member 2201 ispreferably made of a resilient elastomer, which may be thermoplastic orthermoset, or a softenable thermoplastic such as PVC. Thus, the term“flexible” refers to the member having the required flexibility that itmay be inserted into a pipeline from a long reel of flexible supportmember. The support member may be manufactured continuously, and is cutto lengths which are windable onto a reel or spindle, or otherwisestored, i.e. in lengths of 400 to 2000 feet. The device shown in FIG. 21has one principle conduit/cable receiving passageway 2203. In additionthe non-circular passages 2205 may also be used for this purpose. Themember may advantageously be manufactured to include one or moreconductive wires 2207. The purpose of these is to assist robotic ormanual location of the wires by passing a signal through them, as isused to defect underground cable, etc. Once the wire location(s) areknown, the position of the various conduit passages 2203, 2205, will beknown as well. Alternatively, a conductive foil may be bonded to thesurface (top surface or bottom surface or both) to serve the samefunction. Such locating devices may be important, as the structuralliner (2209 in FIG. 22) may partially obscure the exact position of theflexible support member. By using wires, foils, or other devices topinpoint the position of the device, boring tools, etc., may be used toenter the correct passage 2203, 2205 for cable routing, connection,repair, etc., through pipeline wall 2202.

[0102] A preferred device such as that of the type of FIG. 21 is shownin cross-section in FIG. 30, as installed in pipeline 3001, typically ofclay or cementitious material. This device will have a radius R₂ on theinterior surface of the device which is less than the inside radius R¹of the pipeline by the thickness t of the device at maximum thickness.However, the radii R₃ and R₄, increasingly closer to the edges 3009 ofthe device, are preferably, but not necessarily, less. The outside radiiof the device are similarly related. In this manner, the loads placedupon the pipeline by external forces are more evenly distributed ontothe structural liner 3002. The structural liner 3002 shown is of thecure-in-place type, surrounded on its outer surface by flexible sleeve3003. The flexible support 3000 contains a principle integral conduitpassage 3005 and auxiliary conduit passages 3006.

[0103] For example, in an inch (18 inch (46 cm) internal diameter sewerpipe (R¹=18 inches, 46 cm), the flexible support member may extend overapproximately 120° of the diameter of the pipeline, and may have aradius of 16.625 inches (42.2 cm) (R²) at the central portion, and onlya 6″ (15.24 cm) R³ radius at the edges. In a 24 inch (61 cm) pipeline,R² may be 22.5 inches (57.1 cm) while R³ may be 8 inches (20.3 cm).

[0104] In a further embodiment, the flexible cable structure may takethe forms shown in FIG. 31. In FIG. 31, the structure 3100 isinterrupted by notches 3101 between conduit passages 3102. These notchesassist in allowing the flexible cable structure to flex in a directionagainst its normal curvature during entry into the pipeline.

[0105] Certain unique carriers and associated materials are useful inthis embodiment of the invention. As shown in FIG. 32, into a host pipe3201 is installed a conduit 3203. The conduit is flanked on both sidesby “fairing” sections 3205. These may be a single fairing surroundingthe conduit or may be two separate fairings straddling the conduit.These serve to take the load off the conduit and the host pipe wall.Moreover, their use allows the inside of the pipe to be more nearlycircular (distorted circle) free of sudden protuberances, creases, etc.,which would render the pipe more difficult to clean. The fairings may bediscontinuous, or may be continuous. The fairing is held in place by astructural liner 3207, which may be installed simultaneously orsubsequently, i.e. a thermoplastic or thermoset liner.

[0106] A preferred method of cable routing employs the fairings of FIG.21. In this method according to the invention, a flexible cable supportmember is installed in a continuous fashion in an existing pipeline, andmaintained in position as well as isolated from the pipeline contents bya structural liner, as shown in cross-section in FIG. 22. The supportmember may be manufactured continuously, and is cut to lengths which arewindable onto a reel or spindle, or otherwise stored, i.e. in lengths of400 to 2000 feet.

[0107] In a further aspect, the present invention pertains to a methodof providing a means of routing a cable structure in an existingpipeline having an internal radius R′, this method comprisingdiscontinuously installing a plurality of carriers into an existingpipeline, and fixing the carriers in the pipeline, wherein the carriersbear a cable support means or are adapted to bear a cable support means;and where when the carriers bear no cable support means but are insteadadapted to bear a cable support means, the method includes installingcable support means in a plurality of the carriers, said cable supportmeans adapted to receive a cable structure. The carrier comprises ahollow cylindrical sleeve or portion thereof, the cylindrical sleevehaving a coiled or folded configuration whose largest dimension, priorto fixing in said pipeline and in a plane orthogonal and transverse tothe direction of the length of the cylinder, is less than the diameterof the pipeline, the cylindrical sleeve being expandable by unfolding,uncoiling, or a combination thereof, to an external diameter Rsubstantially the same as R′.

[0108] Thus, in one broad aspect, the present invention pertains to acarrier of generally hollow cylindrical cross-section or a segmentthereof which is of a physical size smaller than a pipeline into whichit is to be inserted, and which can be attached to the interior wall ofa pipeline in a substantially discontinuous manner, the carriers bearingor adapted to receive at least one cable support means, such that acable can be routed through an existing pipeline, the cable carriedwithin or mounted to the support means. By such means, and by the methodprovided herein, conventional robotic methods may be used to routecables of all types through existing pipeline infrastructure in a rapidand cost-effective manner.

[0109] By the terms “a” and “an” are meant “one or more” or “at leastone” when used in the claims, unless the context clearly indicatesotherwise. The term “cable structure” is inclusive of both cables andconduit, as discussed earlier. By the term “discontinuously installing”is meant that carriers are installed generally spaced apart in thepipeline, i.e. a continuous carrier is not contemplated hereby. Aninstallation where two or more carriers are in an abutting relationshipis still within the scope of the claims so long as a plurality of totalcarriers have a spaced apart relationship.

[0110] By the term “fixing” in a pipeline is meant positioning in such amanner as to be able to maintain a stable position under normaloperating conditions. Some movement is certainly tolerable. Whenadhesively bonded carriers are used, little movement is expected. By theterm “installing cable support means” is meant the installation of afirst or subsequent support means in a previously installed carrier, thecarrier having been manufactured to receive one or more support means.

[0111] By the term “uncoiling and expansion” is meant that a coiled,generally cylindrical carrier such as that of FIG. 4 (but not limitedthereto) is uncoiled and pressed against the pipeline wall sufficientlyso as to lock together proximate the edges upon release of the expandingforces. By the term “formed integral therewith” as it applies to supportmeans, is meant that the support means has been manufactured with thecarrier or has been bonded or welded to the carrier so as to beessentially inseparable therefrom.

[0112] The terms “grout,” “adhesive,” “mastic” and like terms, whendescribing an adhering substance located between the carrier and thepipeline wall, include cementitious as well as organic adhesives, andare generally used interchangeably. Thus, in the claims, “adhesive”includes “grout.”

[0113] By the term “autolocking means” is meant a passive locking devicewhich serves to lock a coiled carrier in an expanded and generallycylindrical shape, i.e. toward or against the interior wall of apipeline, the autolocking means functioning upon retraction of thecoiled surfaces past each other from a more fully expanded mode.Non-limiting examples of autolocking means are shown in FIGS. 3, 6 and7. An autolocking means does not include a configuration wherein a screwmust be turned, a band shifted or applied, etc.

What is claimed is:
 1. In a method of routing a cable structure withinan existing pipeline having an interior wall of internal radius radiusR′, the improvement comprising: a) installing a discontinuous pluralityof cylindrical sleeves having a coiled or folded configuration such thatthe maximum diameter orthogonal to the length of the cylinder is lessthan R′, said sleeves when unfolded or uncoiled abutting said interiorwall of said pipeline, said cylindrical sleeves having a self-activatinglocking means to lock said sleeves in an unfolded or uncoiledconfiguration, said cylindrical sleeves bearing or adapted to bear atleast one cable support means adapted to receive a cable structure byexerting an expanding pressure against said cylindrical sleevessufficient to activate said locking means; b) installing a discontinuousplurality of portions of a cylindrical sleeve having an outside radiuscorresponding substantially to said internal pipeline radius R′, saidportion of said cylindrical sleeve bearing or adapted to bear at leastone cable support means, comprising adhesively bonding said portions ofsaid cylindrical sleeve, optionally with the aid of fasteners, to theinterior wall of said pipeline; or c) installing a continuous flexiblecable support member configured to have a crescent-shaped cross-sectionfollowing installation, and providing a space for one or more cablestructures, by introducing said flexible support means between theinterior wall of said pipeline and a pipeline liner.
 2. The method ofclaim 1, further comprising: routing a cable structure through saidpipeline, said cable structure supported at intervals along the lengththereof by said support means.
 3. The method of claim 1, wherein saidcarrier comprises a coiled structure having a length in the direction ofthe cylindrical axis and two interlocking edges such that upon uncoilingand expansion of said coiled structure said edges interlock to form acylinder having an outside diameter sufficient by itself or with the useof an elastomeric covering and/or adhesive located between the exteriorof the cylinder and the pipeline wall, to fix the carrier in saidpipeline.
 4. The method of claim 3, wherein said coiled structurecomprises a split cylinder the edges of which are parallel to the axisof said cylinder.
 5. The method of claim 3, wherein said coiledstructure has, on its outermost exterior surface, an elastomericmaterial, an adhesive, or a combination thereof.
 6. The method of claim3, wherein said coiled structure has a cable support means formedintegral therewith.
 7. The method of claim 6, wherein said cable supportmeans comprises a ring, trough or channel adapted in size to receive acable structure.
 8. The method of claim 3, wherein said coiled structureincludes cable support means receiving means.
 9. The method of claim 8,wherein a cable support means is mounted onto said carrier by means ofsaid cable support means receiving means.
 10. The method of claim 1,wherein said carrier is a fiber-reinforced, thermosettableresin-impregnated carrier comprising a folded major portionsubstantially continuous with the pipeline internal diameter whenexpanded and cured, and a cable structure support portion adapted, whenin the cured state, to receive a cable structure.
 11. The method ofclaim 10, wherein said cable support portion comprises a rigid cablestructure receiving support means, whose internal size is substantiallythe same in the uncured state as the size in the cured state.
 12. Themethod of claim 1, wherein said flexible cable support member contains aplurality of conduit passages.
 13. The method of claim 1, wherein saidflexible cable support member has a central portion and two wingportions, the radii of the interior surfaces of said wing portions beingless than the radius of said central portion.
 14. The method of claim 1,wherein said flexible cable support member comprises at least twolongitudinal sections which may be inserted together into a pipeline orseparately into a pipeline, said longitudinal sections positionedadjacent each other prior to inserting said structural liner.
 15. Acarrier suitable for use in the method of claim 1, said carrier bearingor adapted to bear a cable structure receiving means, adapted forinstallation into an existing pipeline of internal radius R′, saidcarrier comprising: a cylindrical sleeve or portion thereof, said sleeveor portion thereof configured to be freely transported through saidpipeline, and attachable to the wall of said pipeline in such mannerthat the external radius of the exterior most portion said carrier andthe internal radius of said pipeline are substantially similar, saidcarrier being comprised of a plastics material, and having an aspectratio of at least 0.2.
 16. The carrier of claim 15, wherein thecylindrical sleeve has integral with a wall thereof, a cable receivingmeans.
 17. The carrier of claim 15, wherein said cable receiving meanscomprises an external portion integral with said wall of said carrierand of the same composition, said cable receiving means having on aninterior wall thereof a metal or ceramic sleeve or sleeve of a plasticsmaterial having a higher melting point than said thermoplastic, saidsleeve substantially preventing reduction on the size of the interior ofsaid cable receiving means when said thermoplastic folded cylinder isheated to a plastic state and expanded outwards toward the pipelinewall.
 18. A carrier suitable for use in the method of claim 1, saidcarrier bearing or adapted to receive at least one cable support means,said carrier comprising a coiled cylindrical metal sleeve bearingautolocking means to lock the sleeve in an expanded condition proximateor adjacent the interior wall of a pipeline, said sleeve optionallyhaving a loading means associated with the exterior surface of saidsleeve, said sleeve having an aspect ratio greater than 0.15 when saidoptional loading means is present, and wherein the aspect ratio isgreater than 0.20 in the absence of a loading means.
 19. The carrier ofclaim 18, wherein said carrier has at least one generally U-shaped cablesupport means in the wall of said sleeve, the closed end of saidU-shaped cable support means directed inwards towards the interior ofsaid sleeve.
 20. A metal carrier for installation in an existingpipeline by the method of claim 1, said carrier bearing or adapted toreceive at least one cable support means, said carrier being in the formof a coiled cylindrical metal sleeve, said metal sleeve havingspring-like projections projecting outwardly away from the exterior ofsaid sleeve and sized to bear against the interior wall of saidpipeline, thereby exerting pressure radially inward on at least aportion of the exterior wall of said sleeve.
 21. A flexible cablesupport member suitable for positioning into an existing pipelinebetween an interior wall of said pipeline and an exterior wall ofsubsequently positioned structural liner by the method claimed in claim1, said flexible cable support member comprising an elongate flexiblemember having a crescent shape in cross-section, said crescent shapecharacterized by an outer convex surface and an inner concave surfaceand containing at least one conduit passage parallel to the length ofsaid elongate flexible member.
 22. The flexible cable support member ofclaim 21, wherein the outer convex surface of said elongate flexiblemember is manufactured to contain at least one notch extendinglongitudinally along the length of said elongate flexible member suchthat the flexibility of said elongate member in a plane orthogonal tothe length thereof is enhanced as compared to an otherwise similarelongate flexible member not having said notch.
 23. The flexible cablesupport member of claim 21, wherein said elongate flexible member ofcrescent cross-section comprises at least two separate longitudinallyextending portions which when positioned adjacent each other, form acrescent shaped structure.
 24. The flexible cable support member ofclaim 21, wherein said support member or a portion thereof has anelectrically conductive portion extending the length or a substantialportion of the length thereof.